Success Story: 100% Recycled Rubber Moulding.
Is a PTFE-coated mould enough to ensure efficient demoulding in the rubber industry?
PTFE (Teflon) coatings are widely used in rubber moulds. Their non-stick properties make part removal easier, reduce residue build-up and help extend the intervals between mould cleaning operations.
However, they are not always sufficient. Their performance depends on the rubber compound and processing conditions. Formulations containing certain abrasive fillers can accelerate coating wear, and some applications still require additional release agents.
This was the starting point for a series of technical trials carried out with our partner in Portugal, at a manufacturer specialising in 100% recycled rubber products, ranging from small components to large moulded parts.
The customer used PTFE-coated moulds on the lower surface and applied silicone release spray to the upper surface before every demoulding cycle.
Our objective was to reduce the frequency of application without compromising part quality.
First trial.
We removed the PTFE coating and treated the mould with ABABOL C (cleaner), ABABOL SHP (sealer) and three coats of ABABOL G (release agent).
The parts were successfully demoulded, but the results did not meet the quality targets we had set for the new release system. Further adjustments were needed.
Second trial.
After evaluating the results, we decided to retain the PTFE coating on the lower part of the mould and focus on improving release performance on the upper surface.
The objective remained the same: achieve more demoulding cycles per application, even if this meant keeping the existing non-stick coating.
We replaced the silicone spray with our semi-permanent release agent, ABABOL TOT SS.
The result: 18 consecutive demoulding cycles from a single application.
- Lower release agent consumption and reduced aerosol use.
- Fewer product applications during production.
- Less need for intervention between moulding cycles.
- Better use of the existing non-stick coating.
The trials confirmed that, for this particular application, retaining the PTFE coating and changing the release agent on the upper surface delivered better results than replacing the entire release system.
This experience reflects how we work at Clades Composites: conducting trials under real production conditions and adapting our solutions to the specific requirements of each process.
Clades Composites | Development and manufacturing of technical solutions for industrial processes.